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Mopar......Can you post some pictures of your control panel and the wiring diagram for your Explorer mill?

I have a 1M motor reversing contactor that I removed from my Boss 5 if you are interested. I recommend you remove yours and take it apart (easy to do) and clean up the contacts. Take an pencil...

BOSS5...thanks for the great posts. This will help other's in the future. I just checked my keyways on the motors that I have (both square and round heatsinks) and they are 3/32. These were from a...

Hey Boss5,
Can you post the part numbers for the motors? I could not cross the motors with your specs. I didn't see a 2-stack E42 motor with 2800oz in and 6A series rating. I like the fact that...

Most wire them in parallel with a bipolar driver.


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Which motors do you have? Superior or Sigma? Round terminal arrangement or square terminal arrangement? What type of motor driver are you using? 4 wire bipolar (series or parallel), 6 wire...

Jim...thanks.

mactec..... I also have a BOSS 4 with the same 2 HP motor. Both of them have the same model number as the one seapacer2 attached in the first post.

I really like the Automation Direct drives. I have used them on a lot of projects at work and I even use them for my own milling machines. I have the GS2-22P0 on my 1HP step pulley Bridgeport...

For what purpose? Spindle control? I do not think I have gone from analog output to PWM without using a PIC or ATMEGA microcontroller. However, I use PWM all the time at work for controlling all...

Can you attach larger image files. These are very difficult to make out when I zoom in.

I bet if you brought in 240V + Neutral + Ground from your wall you could easily do it. You could power each of the outer T2 coils with a different phase and neutral and use these to power the the Y...

I just went out to my shop and rewired the left coil (Z-axis) of the T2 transformer with 120VAC. I removed the jumpers to other coils and had it set up as follows:
230VAC taps (paralleled primary)...

If you provide single phase 120VAC to one coil of the transformer, you will see a much lower output voltage on the secondary. I do not know what it will be because I have not personally tried it. I...

I believe there is a voltage drop because the saturable core reactors are in the circuit between the T2 secondary coil and the bridge rectifiers.

To use the T2 transformer you will have to unwrap a few turns of the secondary because the lowest tap setting is 60VAC. Once that is rectified and filtered there will be 85VDC. That is too much for...

Are you finally deciding on removing the the original BOSS stepper controls and replace them newer drivers? If so, then yes, you can remove almost all of the electronics, especially the 3x saturable...

The SMD board step motor drive signals from the XDI board (X-axis pins 1 and 2, Y-axis pins 3 and 4, Z-axis pins 5 and 6) are fed into the SMD boards at pins 13 and 19. The SMD board splits each...

Did you completely remove the cardcage? Did you hook up the other signals to the K5 connector? Did you hook up the E-stop to an input on the BOB (K5 pins 12 and 15)? The E-stop opto-coupler BOB...

I do not know. I am using MACH 3.

Because it is phase drive. The opto-couplers on the BOB (and the XDI) board have the phase voltage for each motor coil (A or B) connected to the anode of the opto coupler and the cathode of each...

That is a good reference. If you have any questions, just ask. My setup is similar to that one except I made my own breakout board with spare parts I already had lying around.

I have the pin outs but not at my disposal today. I'll post them tomorrow. You basically interface with K5, K6 and K8. I used double row male headers and soldered my cables to them. That way I did...

Basically you remove the card cage and replace it with a breakout board. Then you connect the BOB to the XDI cables. I made my own simple BOB which replicated the XDI circuit. Add a few extras to...

For what it is worth, I am using Mach 3 to run my BOSS 5 with it's original steppers. You need to use the MAX NC CL mode which is quadrature drive.

Do you have any pictures of the rear enclosure components or a picture of the inside of the rear door? I found a few more pictures for you. One is a picture of my rear enclosure door and it shows...

You need to follow the wires until you can locate relay CR5. I believe the back side of that E-stop enclosure only has switches and wiring. The back of the Limit switch should have a BLUE wire 40...

This picture is showing my solenoid bank for speed up and down solenoids (blue end caps) and my spindle brake solenoid (green end cap). You can see that I had to disconnect the incoming WHITE/GREEN...

Both of my Bridgeport CNC machines are knuckle heads. They have both have the pneumatic speed adjuster option and the spindle brake option. The CR5 relay is inside the black box on the left side of...

Do you have the spindle brake option on your machine? If so, wire 214 goes from the output of the E-stop to two locations: Limit Override switch and spindle brake relay contact CR5 (7). When the...

I always install fans and filters in my control boxes. They are installed at the bottom and blow air into the enclosure to pressurize it. The air exhaust is at the top on the opposite side. CFM is...